Perform the work, when the exhaust and cooling system have completely cooled down.

Remove the engine cover.

Remove the front and rear engine under covers.

Remove the air duct (inlet), air cleaner case and mass air flow sensor assembly, air duct and resonator assembly.

Remove the front cross bar. .

CAUTION

Do not spill engine coolant on drive belts.

Drain the engine coolant from the radiator.

Remove the radiator.

Remove the drive belts.

Remove the heated oxygen sensors, as follows:

Disconnect the wiring harness connector of each heated oxygen sensors.

Remove the heated oxygen sensor 1 and 2 on both banks with a heated oxygen sensor wrench .

CAUTION

Be careful not to damage heated oxygen sensor. Discard any heated oxygen sensor which has been dropped from a height of more than 20 in. (0.5m) onto a hard surface such as a concrete floor; replace with a new sensor.

Remove the exhaust mounting bracket between the three-way catalysts (right and left bank) and the transmission.

Evacuate the A/C system. Disconnect the A/C piping from the A/C compressor, then remove the A/C compressor.

Remove the alternator and bracket.

Remove the exhaust front tube.

Remove the steering lower joint at the power steering gear assembly side, and release the steering lower shaft.

Remove the three-way catalysts (right and left bank).

Remove the exhaust manifold covers. (right and left bank)

Loosen the nuts in the reverse order as shown in the figure to remove the exhaust manifold.

NOTE

Disregard No. 9 to No. 12 in removal.

Remove the exhaust manifold gaskets.

CAUTION

Cover engine openings to avoid entry of foreign materials.

Check the surface distortion of each exhaust manifold flange mating surface with a straightedge and feeler gauge. If it exceeds the limit, replace exhaust manifold.

To install:

Install new exhaust manifold gaskets. Install each exhaust manifold gasket with its directional protrusion set upward. Refer to the illustration.

Install the exhaust manifold. Install the exhaust manifold mounting nuts in numerical order as shown in the figure. Tighten nuts No. 1 to No. 4 in two steps. The numerical order No. 9 to No. 12 shown second steps.

Install the exhaust manifold covers. (right and left bank)

Install the three-way catalysts (right and left bank).

Install the steering lower joint at the power steering gear assembly side.

Install the exhaust front tube.

Install the alternator and bracket.

Install the A/C compressor, and reconnect the A/C piping to the A/C compressor.

Install the exhaust mounting bracket between the three-way catalysts (right and left bank) and the transmission.

CAUTION

Be careful not to damage heated oxygen sensor. Discard any heated oxygen sensor which has been dropped from a height of more than 20 in. (0.5m) onto a hard surface such as a concrete floor; replace with a new sensor.

Install the heated oxygen sensors, as follows:

Install the drive belts.

Install the radiator.

Install the front cross bar.

Install the air duct (inlet), air cleaner case and mass air flow sensor assembly, air duct and resonator assembly.

Be careful not to damage heated oxygen sensor. Discard any heated oxygen sensor which has been dropped from a height of more than 20 in. (0.5m) onto a hard surface such as a concrete floor; replace with a new sensor.

Remove the exhaust mounting bracket between the right/left catalytic converter and transmission.

Be careful not to damage heated oxygen sensor. Discard any heated oxygen sensor which has been dropped from a height of more than 20 in. (0.5m) onto a hard surface such as a concrete floor; replace with a new sensor.

Remove water pipes on both the right and left side.

Remove the exhaust manifold cover (right and left bank).

Loosen the mounting nuts in the reverse order shown in the illustration to remove the exhaust manifold.

NOTE

Disregard Nos. 7 and No. 8 in removal.

Remove the exhaust manifold gaskets.

CAUTION

Cover all engine openings to avoid entry of foreign materials.

Check the surface distortion of the exhaust manifold mating surface with a straightedge and feeler gauge. If it exceeds the limit, replace the exhaust manifold.

To install:

Install new exhaust manifold gaskets. On installation, locate the thick side of the port connecting part on the right-hand side (from your viewpoint). Locate the round press in the thick side of the port connecting part above the center level line of port.

Install the manifold and tighten the mounting nuts in the order shown. If the stud bolts were removed, install them and tighten them to the torque specified. Tighten nuts No. 1 and No. 2 in two steps. The numerical order No. 7 and No. 8 shows the second step.

Install the exhaust manifold cover (right and left bank).

Install the water pipes on both the right and left side.

Install the heated oxygen sensor 1 (bank 1 and bank 2).

Install the three way catalyst (right and left bank).

Install the exhaust mounting bracket between the right/left catalytic converter and transmission.